92 YJ rust repair and rebuild - JeepForum.com

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post #1 of 24 Old 03-26-2012, 05:41 PM Thread Starter
cjist1
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92 YJ rust repair and rebuild

I have enjoyed reading many of the YJ build threads in this forum so I decided to post some pics of my winter project.

I have owned this YJ for about 10 yrs now, 6 years ago I installed a Fabtech 4" lift, SYE/CV rear shaft and some other minor things. Over the years the rust has taken its toll. They salt the roads around here so much that it looks like the Bonneville Salt Flats the day after a snow. So this winter I decided to get take care of it the best I could. Here are some pics from when I started a few months ago.






92 YJ 2.5L 5 spd.
75.6hp/100.0 ft,lbs.

1998 Grand Cherokee 5.9 Limited
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post #2 of 24 Old 03-26-2012, 05:46 PM Thread Starter
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The main problems were the rockers and rear frame. The rear frame where the shackles mount were paper thin and I could stick a screwdriver through it with ease. The rockers where pretty much rotted away. I figured I could cut the rear frame off and weld new stuff in. The rest of the frame was actually pretty solid. I ordered new rear frame sections from Safe-T-Cap.

http://autorust.com/store/jeep/wrangler_rear_shackle_mount_section_set_art-042-s?zenid=6851d512934512f3781acc54207360c3

92 YJ 2.5L 5 spd.
75.6hp/100.0 ft,lbs.

1998 Grand Cherokee 5.9 Limited
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post #3 of 24 Old 03-26-2012, 07:07 PM Thread Starter
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So I spent a few days just on the frame. I cut the rear section off and welded on the sections from afe-T-Cap. They fit really well and are much thicker than the factory frame. I found a few other sections of the frame that needed cut out also, I replaced those with some steel plate I had laying around. I cut open part of the frame near the rear axle hump and found that it was caked with dried mud. These boxed frames rust from the inside out...If I could go back in time I would dump a can of WD40 into each side of the frame once a year.








92 YJ 2.5L 5 spd.
75.6hp/100.0 ft,lbs.

1998 Grand Cherokee 5.9 Limited
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post #4 of 24 Old 03-26-2012, 07:29 PM
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Do you have pics of your rocker/seatbelt retractor area repairs?
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post #5 of 24 Old 03-26-2012, 08:58 PM
Apollo12227
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Subscribed! My jeep looks in about the same shape as yours. I have got to chase all the rust out of mine. Keep posting lots of pics as I will probably use this thread. My frame isn't in too bad of shape but my entire rear corners and rocker panels are all bondo I haven't dared dig into yet.
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post #6 of 24 Old 03-26-2012, 11:56 PM Thread Starter
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Quote:
Originally Posted by middyj View Post
Do you have pics of your rocker/seatbelt retractor area repairs?
Here is the only pic that I took of this area, unfortunately my camera focused on something else but you can get the idea. I took a piece of 3/16" steel plate and cut it to fit in this area on the bottom and the verticle piece that rises up to the rear floor. I tied this into the rollbar by cutting out the original piece. The floor towards the front ties into this also. Used a grade 8 bolt and nut to fasten the seatbelt to and also welded a nut to act as the body mount in this location.


92 YJ 2.5L 5 spd.
75.6hp/100.0 ft,lbs.

1998 Grand Cherokee 5.9 Limited
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post #7 of 24 Old 03-27-2012, 07:42 AM
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I am also interested in more pics of this area.
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post #8 of 24 Old 03-27-2012, 04:18 PM Thread Starter
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Spent about 3 days cleaning up the frame with a needle scaler attachment on my air chisel. I also used various grinder wheels and attachments to get all of the loose rust off. Painted the frame with 2 coats of POR 15 and sprayed a top coat of the POR chassis black...they sell the chassis black in spray cans now.




92 YJ 2.5L 5 spd.
75.6hp/100.0 ft,lbs.

1998 Grand Cherokee 5.9 Limited
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post #9 of 24 Old 03-27-2012, 04:26 PM Thread Starter
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Then on to the body. Since most of the rust was on the rockers I decided to boatside it. I ordered the boatside kit from http://www.davescustomsunlimited.com/

There was no better feeling than cutting off those rotted rocker panels. I also cut off a large portion of the rear quarters that were rusted and welded in new, slightly thicker than factory, galvanized sheet. I was happy to see that the sheet metal behind some of the external body was in good shape.






92 YJ 2.5L 5 spd.
75.6hp/100.0 ft,lbs.

1998 Grand Cherokee 5.9 Limited
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post #10 of 24 Old 03-27-2012, 09:56 PM
Apollo12227
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A+ work so far. I love the boat side idea but was always nervous about fabbing my own. $300.00 isn't bad IMO. Can't wait to see what it looks like installed. My rocker panels are absolute cottage cheese the bottom 3" unfortunately my heep came with those god awful rust causing flares that ran down the sides.
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post #11 of 24 Old 03-27-2012, 10:49 PM Thread Starter
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You could certainly fab your own boatsides, but for $300 it seemed like a no brainer to me. They fit really well and sandwich in between the center side body mount. I painted these with 2 coats of POR 15 and then sprayed a top coat of POR Black Coat. I really didnt do any body work over top of the panels that I welded in. I planned on buying the Poison Spyder trail corners so I knew it would be covered up. Plus I didnt want to use any body filler because I have seen how moisture seems to get under it and cause rust. Plus if its too thick it could crack.




92 YJ 2.5L 5 spd.
75.6hp/100.0 ft,lbs.

1998 Grand Cherokee 5.9 Limited
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post #12 of 24 Old 03-27-2012, 10:51 PM
idskot
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Loving that boat side! What's it look like from inside?
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post #13 of 24 Old 03-27-2012, 10:55 PM
alex100
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wow that looks really good! im starting to fix some rust on my yj. i just wish i had the time to lift the tube off the frame to do it right lol
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post #14 of 24 Old 03-27-2012, 11:01 PM Thread Starter
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Quote:
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Loving that boat side! What's it look like from inside?
Thanks. I don't have any pics of the inside right now but I will try to find time to take some tomorrow. The boatsides fit pretty close to the floor. There is not too much of a gap. I am going to install carpet...which will most likely need to be trimmed due to the boat sides.

92 YJ 2.5L 5 spd.
75.6hp/100.0 ft,lbs.

1998 Grand Cherokee 5.9 Limited
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post #15 of 24 Old 03-28-2012, 10:48 AM
alex100
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where did you get the paint? it looks way better then my spray paint job
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